U.S. patent application number 16/642294 was filed with the patent office on 2021-03-11 for computer-controlled remote power module.
The applicant listed for this patent is Smith & Nephew, Inc.. Invention is credited to Cedric CORPA DE LA FUENTE, Branislav JARAMAZ, Constantinos NIKOU.
Application Number | 20210068795 16/642294 |
Document ID | / |
Family ID | 1000005263595 |
Filed Date | 2021-03-11 |
United States Patent
Application |
20210068795 |
Kind Code |
A1 |
NIKOU; Constantinos ; et
al. |
March 11, 2021 |
COMPUTER-CONTROLLED REMOTE POWER MODULE
Abstract
A computer-controlled remote power module is disclosed. The
remote power module may include an enclosure containing a power
converter, a voltage controller, an antenna and a microprocessor.
The voltage controller may be in electrical communication with the
power converter. The microprocessor may be in electrical
communication with the power converter, the voltage controller, and
the antenna. The antenna may be configured to receive wireless
transmissions from a remote computer control system, and provide a
signal to the microprocessor based on the received transmissions.
The microprocessor may receive the signal, and, based on the
signal, selectively cause the voltage controller to provide power.
The remote power module may be configured to selectively provide
power from a battery to a tool, such as a surgical tool.
Inventors: |
NIKOU; Constantinos;
(Monroeville, PA) ; JARAMAZ; Branislav;
(Pittsburgh, PA) ; CORPA DE LA FUENTE; Cedric;
(Gibsonia, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Smith & Nephew, Inc. |
Memphis |
TN |
US |
|
|
Family ID: |
1000005263595 |
Appl. No.: |
16/642294 |
Filed: |
August 30, 2018 |
PCT Filed: |
August 30, 2018 |
PCT NO: |
PCT/US2018/048819 |
371 Date: |
February 26, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62552606 |
Aug 31, 2017 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A61B 2017/00221
20130101; A61B 17/1628 20130101; A61B 90/98 20160201; A61B
2017/00734 20130101; A61B 34/20 20160201; A61B 2017/00212 20130101;
A61B 2034/2055 20160201; A61B 2034/2048 20160201; A61B 17/00
20130101; A61B 17/142 20161101 |
International
Class: |
A61B 17/00 20060101
A61B017/00; A61B 90/98 20060101 A61B090/98; A61B 34/20 20060101
A61B034/20; A61B 17/16 20060101 A61B017/16; A61B 17/14 20060101
A61B017/14 |
Claims
1. A surgical tool system comprising: a remote computer control
system; and a remote power module configured to be releasably
attached to a surgical tool on a first side, to be releasably
attached to a battery module on a second side, to wirelessly
communicate with the remote computer control system, and to control
the provision of power from the battery to the surgical tool.
2. The surgical tool system of claim 1, wherein the remote power
module comprises: an enclosure; a power converter contained within
the enclosure; a voltage controller in electrical communication
with the power converter and contained within the enclosure; an
antenna configured to receive wireless transmissions from the
remote computer control system; and a microprocessor in electrical
communication with the power converter, the voltage controller, and
the antenna, wherein the microprocessor is configured to: receive a
signal from the antenna, and based on the signal, selectively cause
the voltage controller to provide power to the surgical tool.
3. The surgical tool system of claim 2, wherein the enclosure
comprises one or more of polypropylene, polypropylene copolymer,
polymethylpentene, polytetrafluoroethylene resin, polymethyl
methacrylate, ethylene tetrafluoroethylene, ethylene
chlorotrifluoroethlyene, fluoro ethylene propylene, polyether
imide, perfluoroalkoxy, polyketone, polyphenylene oxide,
polysulfone, polyvinyl chloride, polyvinylidene fluoride, silicone,
and thermoplastic elastomers.
4. The surgical tool system of claim 2, wherein the power converter
is configured to receive electrical power from the battery module
at a first voltage, to provide electrical power to the voltage
controller at a second voltage, and to provide electrical power to
the microprocessor at a third voltage.
5. The surgical tool system of claim 2, wherein the voltage
controller comprises: one or more power inputs; one or more power
outputs; a control signal input; and a switch configured to
selectively connect each of the one or more power inputs to a
corresponding one of the one or more power outputs based on a value
of the control signal input.
6. The surgical tool system of claim 2, wherein the antenna is
positioned on the outside of the enclosure.
7. The surgical tool system of claim 2, wherein the antenna is
integrated into the enclosure.
8. The surgical tool system of claim 2, wherein the antenna is
positioned within the enclosure.
9. The surgical tool system of claim 2, wherein: the antenna is
further configured to transmit one or more signals to the remote
computer controller; and the microprocessor is further configured
to establish a wireless communication connection with the remote
computer controller through the antenna.
10. The surgical tool system of claim 2, wherein the remote power
module further comprises: a wired optical tracking emitter in
electrical communication with the microprocessor.
11. The surgical tool system of claim 10, wherein the wired optical
tracking emitter comprises a light emitting diode (LED) array.
12. The surgical tool system of claim 2, wherein the remote power
module further comprises: a radio frequency identification (RFID)
reader configured to read an RFID tag.
13. A remote power module comprising: an enclosure; a power
converter contained within the enclosure; a voltage controller in
electrical communication with the power converter and contained
within the enclosure; an antenna configured to receive wireless
transmissions from a remote computer control system; and a
microprocessor in electrical communication with the power
converter, the voltage controller, and the antenna, wherein the
microprocessor is configured to: receive a signal from the antenna,
and based on the signal, selectively cause the voltage controller
to provide power.
14. The remote power module of claim 13, wherein the enclosure
comprises one or more of polypropylene, polypropylene copolymer,
polymethylpentene, polytetrafluoroethylene resin, polymethyl
methacrylate, ethylene tetrafluoroethylene, ethylene
chlorotrifluoroethlyene, fluoro ethylene propylene, polyether
imide, perfluoroalkoxy, polyketone, polyphenylene oxide,
polysulfone, polyvinyl chloride, polyvinylidene fluoride, silicone,
and thermoplastic elastomers.
15. The remote power module of claim 13, wherein the enclosure is
configured to be releasably attached to a battery on a first side
and releasably attached to a surgical tool on a second side.
16. The remote power module of claim 15, wherein the power
converter is configured to receive electrical power from the
battery at a first voltage, to provide electrical power to the
voltage controller at a second voltage, and to provide electrical
power to the microprocessor at a third voltage.
17. The remote power module of claim 13, wherein the voltage
controller comprises: one or more power inputs; one or more power
outputs; a control signal input; and a switch configured to
selectively connect each of the one or more power inputs to a
corresponding one of the one or more power outputs based on a value
of the control signal input.
18. The remote power module of claim 13, wherein the antenna is
positioned on the outside of the enclosure.
19. The remote power module of claim 13, wherein the antenna is
integrated into the enclosure.
20. The remote power module of claim 13, wherein the antenna is
positioned within the enclosure.
21. The remote power module of claim 13, wherein: the antenna is
further configured to transmit one or more signals to the remote
computer controller; and the microprocessor is further configured
to establish a wireless communication connection with the remote
computer controller through the antenna.
22. The remote power module of claim 13, further comprising: a
wired optical tracking emitter in electrical communication with the
microprocessor.
23. The remote power module of claim 22, wherein the wired optical
tracking emitter comprises a light emitting diode (LED) array.
24. The remote power module of claim 13, further comprising: a
radio frequency identification (RFID) reader configured to read an
RFID tag.
Description
CLAIM OF PRIORITY
[0001] This patent application claims the benefit of priority of
U.S. Provisional Patent Application Ser. No. 62/552,606, titled
"Computer-Controlled Remote Power Module," filed on Aug. 31, 2017,
which is hereby incorporated by reference herein in its
entirety.
TECHNICAL FIELD
[0002] The present disclosure generally relates to
battery-controlled surgical tools. More specifically, the present
disclosure relates to providing a remote power module for use with
battery-controlled surgical tools that is configured to receive
control signals from a control system.
BACKGROUND
[0003] The use of computers, robotics, and imaging to provide aid
during surgery is known in the art. There has been a great deal of
study and development of computer-aided navigation and robotic
systems used to guide surgical procedures. For example, a precision
freehand sculptor employs a robotic surgery system to assist the
surgeon in accurately cutting a bone into a desired shape. In
procedures such as total hip replacement (THR), computer-aided
surgery techniques have been used to improve the accuracy and
reliability of the surgery. Orthopedic surgery guided by images
also has been found useful in preplanning and guiding the correct
anatomical position of displaced bone fragments in fractures along
a good fixation by osteosynthesis.
[0004] In a typical arthroscopic procedure, a practitioner may use
a navigation system, such as an optical or electromagnetic tracking
system, for additional guidance so that any cuts or bone shape
alterations to be made are consistent with a surgical plan. Both
types of tracking systems involve the attachment of sensors to both
the bone to be resected and the cutting instrument to be used by
the surgeon.
[0005] In most systems, cutting tools such as handheld rotary
cutting tools used by a surgeon to prepare a bone surface for
implantation of a prosthetic joint component use a wired connection
to a control system integrated with, for example, the navigation
system to form a computer-aided robotic surgery system. Electrical
power and communication signals from the control system are
delivered to the cutting tool through the wires. In such an
arrangement, the control system can drive the motors on the cutting
tool, receive status information from the motors on the cutting
tool, and receive position information from sensors within the
cutting tool.
[0006] There is an increasing desire for robotically controlled
tools, like a handheld rotary cutting tool, a drill, or an
oscillating cutting tool, to be maximally ergonomic. The
communication cables used in a typical wired system can be heavy
and interfere with use of the handheld rotary tool. However,
transitioning to battery-powered tools creates a new set of issues
as existing battery-powered tools typically lack communication and
remote control modules and are expensive to replace or modify to
work with, and take advantage of, modern computer-aided robotic
surgery systems.
SUMMARY
[0007] This summary is submitted with the understanding that it
will not be used to interpret or limit the scope or meaning of the
present disclosure.
[0008] There is also provided a surgical tool system comprising a
remote computer control system, and a remote power module
configured to be releasably attached to a surgical tool on a first
side, to be releasably attached to a battery module on a second
side, to wirelessly communicate with the remote computer control
system, and to control the provision of power from the battery to
the surgical tool. According to certain embodiments, the remote
power module comprises an enclosure, a power converter contained
within the enclosure, a voltage controller in electrical
communication with the power converter and contained within the
enclosure, an antenna configured to receive wireless transmissions
from the remote computer control system, and a microprocessor in
electrical communication with the power converter, the voltage
controller, and the antenna. The microprocessor is configured to
receive a signal from the antenna, and, based on the signal,
selectively cause the voltage controller to provide power to the
surgical tool.
[0009] According to certain embodiments, the enclosure comprises
one or more of polypropylene, polypropylene copolymer,
polymethylpentene, polytetrafluoroethylene resin, polymethyl
methacrylate, ethylene tetrafluoroethylene, ethylene
chlorotrifluoroethlyene, fluoro ethylene propylene, polyether
imide, perfluoroalkoxy, polyketone, polyphenylene oxide,
polysulfone, polyvinyl chloride, polyvinylidene fluoride, silicone,
and thermoplastic elastomers.
[0010] According to certain embodiments, the power converter is
configured to receive electrical power from the battery module at a
first voltage, to provide electrical power to the voltage
controller at a second voltage, and to provide electrical power to
the microprocessor at a third voltage.
[0011] According to certain embodiments, the voltage controller
comprises one or more power inputs, one or more power outputs, a
control signal input, and a switch configured to selectively
connect each of the one or more power inputs to a corresponding one
of the one or more power outputs based on a value of the control
signal input.
[0012] According to certain embodiments, the antenna is positioned
on the outside of the enclosure, within the enclosure, or is
integrated into the enclosure.
[0013] According to certain embodiments, the antenna is further
configured to transmit one or more signals to the remote computer
controller, and the microprocessor is further configured to
establish a wireless communication connection with the remote
computer controller through the antenna.
[0014] According to certain embodiments, the surgical tool system
further comprises a wired optical tracking emitter in electrical
communication with the microprocessor. According to certain
embodiments, the wired optical tracking emitter comprises a light
emitting diode (LED) array.
[0015] According to certain embodiments, the surgical tool system
further comprises a radio frequency identification (RFID) reader
configured to read an RFID tag.
[0016] There is provided a remote power module comprising: an
enclosure, a power converter contained within the enclosure, a
voltage controller in electrical communication with the power
converter and contained within the enclosure, an antenna configured
to receive wireless transmissions from a remote computer control
system, and a microprocessor in electrical communication with the
power converter, the voltage controller, and the antenna. The
microprocessor is configured to receive a signal from the antenna,
and, based on the signal, selectively cause the voltage controller
to provide power.
[0017] According to certain embodiments, the enclosure comprises
one or more of polypropylene, polypropylene copolymer,
polymethylpentene, polytetrafluoroethylene resin, polymethyl
methacrylate, ethylene tetrafluoroethylene, ethylene
chlorotrifluoroethlyene, fluoro ethylene propylene, polyether
imide, perfluoroalkoxy, polyketone, polyphenylene oxide,
polysulfone, polyvinyl chloride, polyvinylidene fluoride, silicone,
and thermoplastic elastomers.
[0018] According to certain embodiments, the enclosure is
configured to be releasably attached to a battery on a first side
and releasably attached to a surgical tool on a second side.
According to such embodiments, the power converter is configured to
receive electrical power from the battery at a first voltage, to
provide electrical power to the voltage controller at a second
voltage, and to provide electrical power to the microprocessor at a
third voltage.
[0019] According to certain embodiments, the voltage controller
comprises one or more power inputs, one or more power outputs, a
control signal input, and a switch configured to selectively
connect each of the one or more power inputs to a corresponding one
of the one or more power outputs based on a value of the control
signal input.
[0020] According to certain embodiments, the antenna is positioned
on the outside of the enclosure, within the enclosure, or is
integrated into the enclosure.
[0021] According to certain embodiments, the antenna is further
configured to transmit one or more signals to the remote computer
controller; and the microprocessor is further configured to
establish a wireless communication connection with the remote
computer controller through the antenna.
[0022] According to certain embodiments, the remote power module
further comprises a wired optical tracking emitter in electrical
communication with the microprocessor. According to certain
embodiments, the wired optical tracking emitter comprises a light
emitting diode (LED) array.
[0023] According to certain embodiments, the remote power module
further comprises a radio frequency identification (RFID) reader
configured to read an RFID tag.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The accompanying drawings, which are incorporated in and
form a part of the specification, illustrate the embodiments of the
present disclosure and together with the written description serve
to explain the principles, characteristics, and features of the
present disclosure. In the drawings:
[0025] FIG. 1 is an illustration of an operating room with a
computer-aided robotic surgery system in accordance with an
embodiment.
[0026] FIG. 2 depicts a sample circuit diagram for a
battery-operated tool in accordance with an embodiment.
[0027] FIG. 3 depicts a sample diagram of a battery-operated tool
including a remote power module in accordance with an
embodiment.
[0028] FIG. 4 depicts a sample diagram for a remote power module in
accordance with an embodiment.
[0029] FIG. 5 depicts an alternate sample diagram for a remote
power module in accordance with an embodiment.
DETAILED DESCRIPTION
[0030] This disclosure is not limited to the particular systems,
devices and methods described, as these may vary. The terminology
used in the description is for the purpose of describing the
particular versions or embodiments only, and is not intended to
limit the scope.
[0031] As used in this document, the singular forms "a," "an," and
"the" include plural references unless the context clearly dictates
otherwise. Unless defined otherwise, all technical and scientific
terms used herein have the same meanings as commonly understood by
one of ordinary skill in the art. Nothing in this disclosure is to
be construed as an admission that the embodiments described in this
disclosure are not entitled to antedate such disclosure by virtue
of prior invention. As used in this document, the term "comprising"
means "including, but not limited to."
[0032] The embodiments of the present teachings described below are
not intended to be exhaustive or to limit the teachings to the
precise forms disclosed in the following detailed description.
Rather, the embodiments are chosen and described so that others
skilled in the art may appreciate and understand the principles and
practices of the present teachings.
[0033] This disclosure describes a remote power module that
attaches between a standard battery-operated surgical tool and the
battery to provide enhanced control and power modulation. The
remote power module can be configured to connect to the
battery-operated surgical tool in a similar way as the battery
(e.g., a snap lock). The battery can then connect to the remote
power module using a similar connection method. The remote power
module can include communication and power modulation/switching
electronics configured to support a wireless communications link
with, for example, a remote control system integrated into a
computer-aided robotic surgery system. Thus, the remote control
system can provide control signals to the module for controlling
the battery-operated tool.
[0034] In certain implementations, such a remote power module can
be used to implement remote control functionality into a standard
battery-operated surgical tool. This could allow, for example, a
standard surgical drill to be disabled according to information
received by a navigation system integrated into the computer-aided
robotic surgery system. In certain implementations, if the
navigation system, while tracking the drill using external tracking
hardware, determines that the position or trajectory of the drill
is incorrect relative to a registered surgical plan (registered
with the computer-aided robotic surgery system), the control system
can disable the drill so that the surgeon does not inadvertently
drill in a position or at a trajectory that is not in accordance
with the registered surgical plan.
[0035] Such an arrangement including a standard battery-operated
surgical tool and a remote power module has several advantages. The
battery remains standard, and can be removed and charged using
existing chargers and charging techniques. A new battery can be
swapped in, and, assuming the remote power module is still operably
connected to the battery-operated surgical tool, the surgery can
continue as before with the enhanced control of the surgical tool.
Additionally, battery-operated tools that are designed for use in a
surgical environment are typically designed to be completely sealed
and more impact resistant to accommodate repeated cleaning and
sterilization cycles. Thus, with the remote power module as
described herein, the battery-operated surgical tools can remain
rugged while maintaining their simplified designs (described in
more detail below in regard to FIG. 2), because the various control
and communication circuitry is integrated into the remote power
module. With such an arrangement, damage to the control and
communication circuitry results in replacement of the remote power
module rather than the entire tool.
[0036] As noted above, a computer-aided robotic surgery system can
include various components such as a remote control system and a
navigation system. In certain embodiments, the remote control
system can include one or more processing devices,
firmware-controlled microcontrollers, power systems, communication
systems, storage mediums, and other related components. In some
examples, the navigation system can be operably connected to the
remote control system and be particularly adapted for surgical
procedures that utilize tracking devices, such as the NAVIO.RTM.
surgical navigation system. NAVIO is a registered trademark of BLUE
BELT TECHNOLOGIES, INC. of Pittsburgh, Pa.
[0037] In alternative embodiments, the disclosure describes a
remote power module that attaches between a standard
battery-operated tool and the battery to provide enhanced control
and power modulation. The remote power module can be configured to
connect to the battery-operated tool in a similar way as the
battery (e.g., a snap lock). The battery can then connect to the
remote power module using a similar connection method. The remote
power module can include communication and power
modulation/switching electronics configured to support a wireless
communications link with, for example, a remote control system
integrated into a smart phone or tablet device. Thus, the remote
control system can provide control signals to the module for
controlling the battery-operated tool.
[0038] In alternate implementations, the remote power module can be
used to implement remote control functionality into any
battery-operated tool, such as a power drill, power driver, power
impactor, or reciprocating saw. Similar to previously described
embodiments, battery-operated hand tools could be controlled with
information received from an optical navigation system that tracks
the tool and provides feedback on its position or trajectory.
Similarly, the remote control unit could contain an embedded
orientation sensing electronics, including one or a combination of
accelerometers, magnetometers, gyroscopes, or inertial measurement
units. Batter power provided to the tool can be modulated on the
tool's orientation relative to gravity. For example, in an
embodiment in which the tool is a power drill, the control system
can disable the drill if the orientation of the tool is not normal
to the direction of the acceleration of gravity.
[0039] An orientation control scheme can be developed that
considers the tool target orientation, which can also be provided
by one or a combination of accelerometers, magnetometers,
gyroscopes, or inertial measurement units. The tool target
orientation sensing instrumentation can be a standalone unit or
contained in a consumer electronic device, such as a smart phone or
tablet. Battery power provided to the tool can be modulated based
on the tool's orientation relative to the target orientation. For
example, if the tool is a power drill and the target is an angled
surface, the control system can disable the drill if its
orientation is not perpendicular to the angled surface.
[0040] FIG. 1 illustrates components of a computer-aided robotic
surgery system 100 that can be configured to perform knee movement
tracking according to some embodiments. The computer-aided robotic
surgery system 100 can assist a surgeon in performing certain
surgical procedures, such as joint revision surgery.
[0041] The computer-aided robotic surgery system 100 can include a
computer system 110 to provide a display for viewing location data
provided by optical trackers 112 as read by a position tracker 114.
The optical trackers 112 and position tracker 114 can provide data
relevant to the precise location of bones in a knee joint. In
certain embodiments, the position tracker 114 can be an optical
camera that can detect tracking spheres located on the optical
trackers 112 in order to gather location data for a patient upon
which a procedure is to be performed. The position tracker 114 can
be any suitable tracking system, such as those known in the art to
use active trackers, passive trackers, optical trackers,
electromagnetic trackers, infrared camera systems, or other similar
systems.
[0042] Additionally, as noted above, the computer system 110 can be
configured to provide communication and control signals to a
surgical tool, as well as receive information related to the
position/orientation of the surgical tool from the optical trackers
or from the surgical tool itself. In certain implementations, the
computer-aided robotic surgery system 100 can include additional
computing systems. For example, the computer-aided robotic surgery
system 100 can include a first computing system configured to
compute navigation information, such as patient position
information and surgical tool information, and a second computing
system configured to compute remote control information related to
operation of one or more surgical tools according to a registered
surgical plan.
[0043] FIG. 2 illustrates a sample battery-powered surgical tool
200. In this example, the surgical tool 200 is an oscillating saw.
However, it should be noted that an oscillating saw is shown by way
of example only, and any battery-powered surgical tool can be used
with the techniques described herein. As examples, the
battery-powered surgical tool can include a drill or a rotary
cutting tool.
[0044] Referring again to FIG. 2, when in operation, or when ready
for operation, the surgical tool 200 can be operably connected to
battery 202. The battery 202 and the surgical tool 200 can be
designed and manufactured to securely connect using a releasable
mechanism such as a snap fit or a friction fit. However, because
the surgical tool 200 and battery 202 are configured and designed
to be used in clean environments such as operating rooms, the
surgical tool 200 and the battery are designed to be cleaned and
sterilized after each use. Examples of such surgical tools can be
found in U.S. Pat. No. 5,263,972 entitled "Surgical Handpiece Chuck
and Blade," the content of which is incorporated herein by
reference.
[0045] As shown in FIG. 2, the battery 202 can include positive and
negative terminals 204. When the battery 202 is attached to the
surgical tool 200, the terminals 204 can electrically connect to
internal wiring 206 within the surgical tool 200. In certain
implementations, the wiring 206 can terminate in exposed copper
plates, or plates made from another similar conductive metal, that
are positioned such that, when the battery 202 is attached to the
surgical tool 200, the terminals 204 abut the plates, thereby
electrically connecting the stored electrical energy contained
within the battery 202 to the wiring 206. The wiring 206 can be
configured such that it establishes an electrical connection
between mechanical components 208 within the surgical tool 200 with
the battery 202. In certain implementations, the mechanical
components 208 can include an electric motor configured to produce
a rotational motion from the electrical energy contained within the
battery 202. With an oscillating saw as shown in FIG. 2, the
mechanical components 208 can also include a drive mechanism that
is configured to convert the rotation motion of the motor to an
oscillating motion for driving a saw blade 212.
[0046] The surgical tool 200 also can include a switch or button
210. The button 210 can be operably connected to an electrical
connector configured to short a gap in the wiring 206, thereby
activating one or more electrical components contained within the
surgical tool 200 (e.g., the electric motor as described
above).
[0047] In certain implementations, the surgical tool 200 can
include additional electrical components such as an external light
that can be operated by actuation of button 210 or via an alternate
actuation mechanism such as a separate switch (not shown in FIG.
2).
[0048] FIG. 3 illustrates the surgical tool 200 of FIG. 2, with an
included remote power module 300. As shown in FIG. 3, the remote
power module 300 can be positioned between the battery 202 and the
surgical tool 200. The remote power module 300 can be designed such
that it fastens to the surgical tool 200 in the same manner as the
battery 202 would otherwise connect to the surgical tool 200.
Similarly, the remote power module 300 can be designed such that
the battery 202 connects to the remote power module 300 in the same
manner as the battery 202 would normally connect to the surgical
tool 200.
[0049] The remote power module 300 can be configured to receive
power from the battery 202 via the terminals 204 and provide a
control signal to the surgical tool 200 via wiring 206. However, it
should be noted that, other than the introduction of the remote
power module 300, the design of both the surgical tool 200 and the
battery 202 remains unchanged from FIG. 2 to FIG. 3. Thus, through
the addition of the remote power module 300, the functionality of
the surgical tool 200 can be quickly and easily improved as
compared to modifying the internal components of the surgical tool
200 itself. The specific architecture and added functionality of
the remote power module is described in the following discussion of
FIG. 4.
[0050] FIG. 4 illustrates a component view of the remote power
module 300 as described in regard to FIG. 3. As noted above, the
remote power module 300 can be configured for use in a clean
environment such as an operating room. As such, one of ordinary
skill in the art would understand the remote power module 300 can
be designed and manufactured to be rugged and able to be
cleaned/sterilized. To provide for such a design, the various
components of the remote power module 300 can be integrated into an
enclosure 400. The enclosure 400 can be manufactured from a durable
material that is easy to clean and sterilize. For example, the
enclosure 400 can be manufactured from a high-strength and durable
plastic such as polycarbonate. In other implementations, the
enclosure 400 can be manufactured from polymers such as
polypropylene (PP), polypropylene copolymer (PPCO),
polymethylpentene (PMP), polytetrafluoroethylene (PTFE) resin,
polymethyl methacrylate (PMMA or acrylic), ethylene
tetrafluoroethylene (ETFE), ethylene chlorotrifluoroethlyene
(ECTFE), fluoro ethylene propylene (FEP), polyether imide (PEI),
perfluoroalkoxy (PFA), polyketone (PK), polyphenylene oxide (PPO),
polysulfone (PSF), polyvinyl chloride (PVC), polyvinylidene
fluoride (PVDF), silicone, and thermoplastic elastomers (TPE). In
some embodiments, the enclosure can be encapsulated in
silicone.
[0051] As shown in FIG. 4, the enclosure 400 can be configured to
house the various electrical components of the remote power module
300. The remote power module 300 can include a power converter 402,
such as a voltage regulator, operably connected to and configured
to receive power from a battery (e.g., battery 202 as described
above). As shown in FIG. 4, the power converter 402 can be operably
connected to the battery and configured to receive power signal +Vo
and return power signal -Vo to the battery. In certain
implementations, the power converter 402 can be configured to
receive power from the battery at a particular voltage (e.g., 18V
or 20V).
[0052] The power converter 402 can be configured to split the
received power, and output the power to additional components.
Additionally, the power converter 402 can include one or more
feedback control loops and various voltage regulating/modulating
components to alter the supplied voltage value as might be needed
for additional components. For example, as shown in FIG. 4, the
power converter 402 can be configured to provide an input voltage
to both a voltage controller 404 (via signal +Vm) as well as to a
microprocessor 406 (via signal +Vf). In certain implementations,
voltage controller 404 can be configured to act as a switching
component configured to selectively provide power to a
battery-operated surgical tool (e.g., surgical tool 200 as
described above). As such, the power converter 402 can be
configured to provide a power signal +Vm to the voltage controller
404 that is the same voltage as the output of the battery (e.g.,
the same voltage as +Vo). However, in some examples, the
microprocessor 406 can operate at a lower voltage than +Vo. In such
examples, the power converter 402 can be configured to reduce the
input voltage +Vo to the appropriate voltage for operating the
microprocessor 406. In certain implementations, the microprocessor
406 can be an ARM (advanced RISC machine) microprocessor configured
to implement an ARM instruction set for handling multiple
simultaneous processes. Such microprocessors typically operate with
a 5V input. In such an implementation, the power converter 402 can
be configured to lower the voltage of input signal +Vo to 5V, and
output an appropriate 5V input signal +Vf.
[0053] As noted above, the voltage controller 404 can be configured
to operate as a switch for selectively providing a power signal
+Vm' to operate the surgical tool. The switching mechanism of the
voltage controller 404 can be operated via a control signal 408
from the microprocessor 406. For example, the microprocessor 406
can receive instructions from a remote control system that a
surgical tool is to be operated under normal circumstances. In such
an example, the microprocessor 406 can instruct the voltage
controller 404 via signal 408 to close the switch, thereby
providing power signal +Vm' to the surgical tool. The surgical tool
can then operate normally, e.g., turn on in response to actuation
of a button or similar activation mechanism by a user of the
surgical tool. However, if the microprocessor 406 receives
instructions from the remote control system that the surgical tool
is to stop functioning (e.g., the surgical tool is cutting or
drilling outside of an appropriate area), the microprocessor 406
can instruct the voltage controller 404 via signal 408 to open the
switch, thereby interrupting power signal +Vm' to the surgical tool
and stopping operation of the surgical tool.
[0054] To provide communications between the microprocessor 408 and
a remote control system, the remote power module 300 can further
include an antenna 410 operably connected to the microprocessor
406. The microprocessor 406 can be configured to send and receive
radio communication signals to/from the antenna 410 to communicate
with the remote control system. The microprocessor 406 can be
designed to establish a wireless communication connection with the
remote control system according to a standard communication
protocol such as near-field communications (NFC), Bluetooth.RTM.,
ZigBee, Wi-Fi, or another similar wireless communication
standard.
[0055] As shown in FIG. 4, the antenna 410 can be positioned on the
outside of the remote power module 300. However, this is shown by
way of example only. Depending upon the design of the remote power
module 300, the position of the antenna 410 can vary accordingly.
For example, if the enclosure 400 is made from a material that
wireless communication signals can penetrate, the antenna 410 can
be positioned within the enclosure 400, thereby reducing the number
of openings in the enclosure 400. If the enclosure 400 is made from
a material that may interfere with the wireless communication
signals, the antenna 410 can be integrated into the enclosure 400
itself. For example, the antenna 410 can be designed as one or more
copper traces embedded into the material of the enclosure 400. In
some implementations, the microprocessor 406 can include an
integrated antenna and communication circuitry, and may not require
any additional antennas.
[0056] In operation, the components of remote power module 300 can
be initiated when the remote power module 300 is operably connected
to a battery. Upon initialization, the power converter 402 can
generate the appropriate output signals +Vm and +Vf. Similarly,
upon initialization, the microprocessor 406 can establish a
wireless communication connection with the remote control system
and, in response to instructions from the remote control system,
signal the voltage controller 404 to either switch into operating
mode or into non-operating mode (e.g., either provide power to the
surgical tool for standard operation, or interrupt power to the
surgical tool). The user of the surgical tool can then use the
surgical tool to carry out a registered surgical plan with
oversight of the operation of the surgical tool by the remote
control system.
[0057] In an embodiment, a device may be mounted in or on an
autoclavable material, encapsulated in a silicone housing that may
be easily sterilized, and removably engagable with a tool. The
autoclavable material allows the device to be sterilized or
autoclaved a plurality of times without degradation of the
material, internal components, or operational performance. For
example, the housing may include an internal body or mounting
structure (not shown) on components may be mounted. The internal
body may be formed of a material that can be subjected to
sterilization processes, such as autoclaving. For example, the
internal body can be formed from a glass-reinforced epoxy laminate,
such as a NEMA grade G-11 glass reinforced epoxy laminate
(VETRONITE G11) or equivalent. The internal body may be surrounded
by a first covering formed from a first material, such as an
over-molding of VMQ silicone material #71385C available from
Minnesota Rubber & Plastics, 1100 Xenium Lane N., Minneapolis,
Minn. 55441. The housing may also include a second covering that
may provide an additional layer of protection or insulation at an
outer edge of the housing. The second covering may be formed from a
second material, such as an over-molding of VMQ silicone material
#71325C available from Minnesota Rubber & Plastics, 1100 Xenium
Lane N., Minneapolis, Minn. 55441. The housing may further include
a coupling member that passes through the internal body and that
engages one or more attachable components. The coupling member may
be formed from polysulfone, such as a GEHR PPSU polyphenylsulfone
RAL 9005 Black (Solvay Radel R-5500) or equivalent, and can be at
least partially covered by the first covering.
[0058] In some implementations, a remote power module can include
external tracking hardware in the design of its external enclosure.
For example, as shown in FIG. 5, a remote power module 500 can
include an array of active LED markers that are detectable by a
navigation system such as those described herein. In another
embodiment, reflective spheres can be attached to the power module
500.
[0059] As shown in FIG. 5, the remote power module 500 includes
similar components to remote power module 300 as described above.
For example, the remote power module 500 includes a power converter
502 operably connected to a battery (not shown in FIG. 5) and
configured to produce signal +Vm for providing power to a voltage
controller 504 and signal +Vf for providing power to a
microprocessor 506. As described above, microcontroller 506 can be
configured to provide a control signal via signal 508 to the
voltage controller 504 to either provide or interrupt power to a
surgical tool operably connected to the remote power module 500.
Additionally, the remote power device 500 can include an antenna
510 operably connected to the microprocessor 506.
[0060] In certain implementations, the remote power module 500 can
also include a wired optical tracking emitter 512. As shown in FIG.
5, the tracking emitter 512 can be implemented as an LED array
including multiple infrared LEDs configured to strobe, blink, or
otherwise emit light in a particular pattern upon receiving
instructions from the microprocessor 506. A navigation system can
then track and monitor the position of the remote power module 500
and, by extension, the surgical tool being used.
[0061] For example, in operation, a surgeon or other operator can
connect the remote power module 500 to a surgical tool, and then
connect a battery to the remote power module 500. Various
components such as the power converter 502 and the microprocessor
506 of the remote power module 500 can initiate operation. As noted
above, upon initialization, the microprocessor 506 can establish a
wireless communication connection to a remote control system. Upon
establishing the connection, a navigation system in communication
with the remote control system can determine a location and
orientation of the remote power module 500 via the tracking emitter
512.
[0062] Upon determining a location of the remote power module, the
remote control system can prompt the surgeon or other operator to
identify what type of surgical tool has been connected to the
remote power module 500. Upon receiving a selection of the type of
surgical tool connected, the remote control system can load various
information about that surgical tool such as dimensional
information. Additionally, depending upon what type of surgical
tool is being used, the remote control system can prompt for
additional information. For example, if a drill is being used, the
remote control system can prompt for additional information such as
drill bit diameter and length. This information can be used to
determine the position of the tip of the drill bit relative to the
tracking emitter 512, thereby resulting in the navigation system
accurately tracking the drill bit.
[0063] It should be noted that prompting for the type of surgical
tool being used is provided by way of example only. Additional
techniques can be used to identify what type of surgical tool is
being used. For example, each surgical tool can have a tag such as
an RFID tag. The remote power module 500 can include an RFID reader
that is configured to read the tag associated with the surgical
tool and identify what type of surgical tool is being used. This
information can then be sent by the microprocessor 506 to the
remote control system. Alternatively, the microprocessor 506 and/or
the voltage controller 504 can be configured to monitor various
electrical characteristics of the power being used by the surgical
tool such as electrical current draw. The microprocessor 506 and/or
the voltage controller 504 can analyze the electrical
characteristics to determine what type of surgical tool is being
used.
[0064] In certain implementations, the surgeon or operator of the
surgical tool also can be prompted to perform registration and
calibration of the surgical tool. Rather than being prompted to
input specific information about the tool (e.g., drill bit length
and diameter), the surgeon can be instructed to position the
surgical tool in a specific manner. For example, if using a drill,
the surgeon can be instructed to position the drill such that the
drill bit tip is touching a fiduciary marker whose position is
known to the navigation system. Upon touching the fiduciary marker,
the navigation system can use the known position of the fiduciary
marker in combination with information from the tracking emitter to
determine a position and orientation of the surgical tool.
[0065] In certain implementations, by including an active tracking
emitter such as tracking emitter 512 into a remote power module, an
existing surgical tool can be both tracked and controlled without
external clamping of tracking hardware onto the surgical tool
itself, or modifying the internal components of the surgical tool.
Such an arrangement provides for easy modification and improvement
of existing tools.
[0066] It should be noted that active optical tracking emitters are
described by way of example only. In some implementations, a remote
power module as described herein can include additional tracking
hardware, such as reflective or other similar visual markers,
integrated into the design of its external case or enclosure. Such
reflective or visual markers can be positioned about the external
case of the remote power module such that a navigation system can
track the tool associated with the remote power module regardless
of the position or orientation that the tool is in.
[0067] In some examples, if there is enough power capacity in the
battery, additional functionality can be incorporated into the
remote power module as described herein. For example, for a
handheld cutting device, such as a rotary cutting device, using a
bur to cut bone, the remote power module also can be configured to
provide motor control signals received from a control system to
drive a guard motor, thereby moving the bur guard and exposing the
bur for cutting. Similarly, if a navigation system detects that the
bur is approaching an area that is not to be removed, the control
system can send a command to the remote power module to shut off
power to the bur and instruct the guard motor to move the bur guide
such that the bur is covered or otherwise unable to continue
removing bone.
[0068] Additionally, in certain implementations, the remote power
module can also receive feedback information from, for example, a
motor or motor controller. The feedback can include various
information related to the operation of a tool, such as speed and
torque information. The speed information can be used by the remote
power module to more accurately control the speed of the tool by
calibrating its motor control signals. In some examples, torque
information can be used as an input to a torque limiting circuit
implemented by, for example, an onboard microcontroller in the
remote power module that prevents a drill from exerting too much
torque on a bone or soft tissue. In another example, torque
information can be used as an input to a torque limiting circuit
implemented by, for example, an onboard microcontroller in the
remote power module that prevents a screw driver from exerting too
much torque on a screw or a half-pin.
[0069] It should be noted that the remote power module as described
herein is described as being configured to be used with a surgical
tool by way of example only. The remote power module, and the
associated features and functionality, as described herein can be
used with any battery-powered tool or device to provide various
added benefits and functions.
[0070] In the above detailed description, reference is made to the
accompanying drawings, which form a part hereof. In the drawings,
similar symbols typically identify similar components, unless
context dictates otherwise. The illustrative embodiments described
in the detailed description, drawings, and claims are not meant to
be limiting. Other embodiments may be used, and other changes may
be made, without departing from the spirit or scope of the subject
matter presented herein. It will be readily understood that various
features of the present disclosure, as generally described herein,
and illustrated in the Figures, can be arranged, substituted,
combined, separated, and designed in a wide variety of different
configurations, all of which are explicitly contemplated
herein.
[0071] The present disclosure is not to be limited in terms of the
particular embodiments described in this application, which are
intended as illustrations of various features. Many modifications
and variations can be made without departing from its spirit and
scope, as will be apparent to those skilled in the art.
Functionally equivalent methods and apparatuses within the scope of
the disclosure, in addition to those enumerated herein, will be
apparent to those skilled in the art from the foregoing
descriptions. Such modifications and variations are intended to
fall within the scope of the appended claims. The present
disclosure is to be limited only by the terms of the appended
claims, along with the full scope of equivalents to which such
claims are entitled. It is to be understood that this disclosure is
not limited to particular methods, reagents, compounds,
compositions or biological systems, which can, of course, vary. It
is also to be understood that the terminology used herein is for
the purpose of describing particular embodiments only, and is not
intended to be limiting.
[0072] With respect to the use of substantially any plural and/or
singular terms herein, those having skill in the art can translate
from the plural to the singular and/or from the singular to the
plural as is appropriate to the context and/or application. The
various singular/plural permutations may be expressly set forth
herein for sake of clarity.
[0073] It will be understood by those within the art that, in
general, terms used herein, and especially in the appended claims
(for example, bodies of the appended claims) are generally intended
as "open" terms (for example, the term "including" should be
interpreted as "including but not limited to," the term "having"
should be interpreted as "having at least," the term "includes"
should be interpreted as "includes but is not limited to," et
cetera). While various compositions, methods, and devices are
described in terms of "comprising" various components or steps
(interpreted as meaning "including, but not limited to"), the
compositions, methods, and devices also can "consist essentially
of" or "consist of" the various components and steps, and such
terminology should be interpreted as defining essentially
closed-member groups. It will be further understood by those within
the art that if a specific number of an introduced claim recitation
is intended, such an intent will be explicitly recited in the
claim, and in the absence of such recitation no such intent is
present.
[0074] For example, as an aid to understanding, the following
appended claims may contain usage of the introductory phrases "at
least one" and "one or more" to introduce claim recitations.
However, the use of such phrases should not be construed to imply
that the introduction of a claim recitation by the indefinite
articles "a" or "an" limits any particular claim containing such
introduced claim recitation to embodiments containing only one such
recitation, even when the same claim includes the introductory
phrases "one or more" or "at least one" and indefinite articles
such as "a" or "an" (for example, "a" and/or "an" should be
interpreted to mean "at least one" or "one or more"); the same
holds true for the use of definite articles used to introduce claim
recitations.
[0075] In addition, even if a specific number of an introduced
claim recitation is explicitly recited, those skilled in the art
will recognize that such recitation should be interpreted to mean
at least the recited number (for example, the bare recitation of
"two recitations," without other modifiers, means at least two
recitations, or two or more recitations). Furthermore, in those
instances where a convention analogous to "at least one of A, B,
and C, et cetera" is used, in general such a construction is
intended in the sense one having skill in the art would understand
the convention (for example, "a system having at least one of A, B,
and C" would include but not be limited to systems that have A
alone, B alone, C alone, A and B together, A and C together, B and
C together, and/or A, B, and C together, et cetera). In those
instances where a convention analogous to "at least one of A, B, or
C, et cetera" is used, in general such a construction is intended
in the sense one having skill in the art would understand the
convention (for example, "a system having at least one of A, B, or
C" would include but not be limited to systems that have A alone, B
alone, C alone, A and B together, A and C together, B and C
together, and/or A, B, and C together, et cetera). It will be
further understood by those within the art that virtually any
disjunctive word and/or phrase presenting two or more alternative
terms, whether in the description, claims, or drawings, should be
understood to contemplate the possibilities of including one of the
terms, either of the terms, or both terms. For example, the phrase
"A or B" will be understood to include the possibilities of "A" or
"B" or "A and B."
[0076] In addition, where features of the disclosure are described
in terms of Markush groups, those skilled in the art will recognize
that the disclosure is also thereby described in terms of any
individual member or subgroup of members of the Markush group.
[0077] As will be understood by one skilled in the art, for any and
all purposes, such as in terms of providing a written description,
all ranges disclosed herein also encompass any and all possible
subranges and combinations of subranges thereof. Any listed range
can be easily recognized as sufficiently describing and enabling
the same range being broken down into at least equal halves,
thirds, quarters, fifths, tenths, et cetera. As a non-limiting
example, each range discussed herein can be readily broken down
into a lower third, middle third and upper third, et cetera. As
will also be understood by one skilled in the art all language such
as "up to," "at least," and the like include the number recited and
refer to ranges that can be subsequently broken down into subranges
as discussed above. Finally, as will be understood by one skilled
in the art, a range includes each individual member. Thus, for
example, a group having 1-3 cells refers to groups having 1, 2, or
3 cells. Similarly, a group having 1-5 cells refers to groups
having 1, 2, 3, 4, or 5 cells, and so forth.
[0078] Various of the above-disclosed and other features and
functions, or alternatives thereof, may be combined into many other
different systems or applications. Various presently unforeseen or
unanticipated alternatives, modifications, variations or
improvements therein may be subsequently made by those skilled in
the art, each of which is also intended to be encompassed by the
disclosed embodiments.
* * * * *